Bitumen Emulsion Plants

What is Bitumen Emulsion Plant?

Bitumen Emulsion Plants are specialized production facilities designed to create a homogenous mixture of bitumen, water, and emulsifiers. These emulsions are essential for modern road construction, maintenance, waterproofing applications, and surface treatments.

Vimpo offers high-quality, reliable, and customizable bitumen emulsion systems that meet international standards and adapt to diverse operational needs.

Why Choose Vimpo Emulsion Plants?

• Over 25 years of experience in asphalt and bitumen processing solutions
• Export to over 40 countries
• TÜBİTAK-supported R&D background
• In-house manufacturing of pumps, emulsifier mills, and dosing systems
• CE-certified equipment built with ISO 3834 and EN 1090 standards

Where to Use Bitumen Emulsions?

• Road construction (prime coats, tack coats)
• Surface dressing for highways and rural roads
• Cold mix asphalt production
• Waterproofing applications in building construction
• Soil stabilization for agricultural and access roads
• Crack sealing and repair works

Why Use Bitumen Emulsions?

• Environmentally friendly (water-based, lower emissions)
• Cold application reduces energy costs
• Faster project execution compared to traditional hot mix asphalt
• Better penetration into aggregates and surfaces
• Suitable for remote locations without heating infrastructure
• Safer handling and storage compared to hot bitumen

Technical Overview of Bitumen Emulsion Plants

Types of Bitumen Emulsion Plants

• VEP 5 Bitumen Emulsion Plant
• VEP 10 Bitumen Emulsion Plant
• VEP 20 Bitumen Emulsion Plant

System Features of Bitumen Emulsion Plants

• Batch and continuous production modes
• Acid (HCl),Emulsifier, CaCl₂, Latex, Starch, and Flux Oil dosing units
• Gravity and magnetic dosing systems
• Skid-mounted or containerized solutions
• Easy operation and minimal maintenance requirements
• Expandable design for future capacity increases

Application Areas of Bitumen Emulsion Plants

• Surface dressing
• Prime and tack coats
• Cold mix asphalt production
• Waterproofing membranes
• Stabilization projects

Optional Equipment of Bitumen Emulsion Plants

• Latex dosing units for polymer-modified emulsions
• CaCl₂ dosing units for setting control
• Peristaltic or lobe pumps depending on product viscosity
• Cleaning and flushing systems

Quality Commitment

All Vimpo Bitumen Emulsion Plants are designed, manufactured, and tested according to:

• ISO 3834 (Welding Quality Requirements)
• EN 1090 (Structural Fabrications)
• CE Marking Requirements
• International bitumen and emulsion standards

Project Support

Vimpo provides:

• Turnkey Project Execution (including bitumen storage and heating systems)
• Installation and commissioning
• Technical training for operators
• After-sales support and spare parts

A Compact Bitumen Emulsion Plant

The Bitumen Emulsion Plant can optionally be produced with thermal oil or electric heating. It features a stainless steel, electrically heated WAE tank (Water-Acid-Emulsifier). An integrated bitumen tank and thermal oil system are optionally available. It is equipped with a weighing system supported by load cells.

The Emulsion Plants include an anti-foaming collector. Thanks to its PLC-controlled system located in an easily accessible control panel, it offers a precise production process and control. The user-friendly touch screen on the control panel allows easy monitoring and management of the production process.

Thanks to the dosing system of Vimpo Bitumen Emulsion Plants and the use of flowmeters for loading acid and emulsifier into the tank, the need for a bunker is eliminated, allowing for a more compact design.

The Bitumen Emulsion Plant has a compact and bunker-free structure with a stainless steel acid and emulsifier dosing system equipped with flowmeters. The Vimpo Bitumen Emulsion Plant features a compact container-type design that allows for easy transport and installation. (Can be shipped in a 40’ DC container.)

The Vimpo brand bitumen pump stands out with its quiet operation and high efficiency. The pump ensures uninterrupted transfer at a flow rate of 50 m³/h. The bitumen pump, produced by VIMPO, operates in full harmony with VIMPO-manufactured valves and filters. The mechanical seals used in the pump provide excellent performance in terms of impermeability.

It is designed in accordance with long-lasting, operator-friendly, and high-efficiency standards.

How to Operate a Bitumen Emulsion Plant?

The emergency stop systems located on the bitumen emulsion plant are automatically controlled by the automation system. If there is no emergency, the control phase is activated throughout the entire plant.

The valve that directs the produced emulsion either to the storage tank or the distributor is opened. After these steps, material preparation must be completed before starting production. These preparations include filling the water tank and heating it to the desired temperature, as well as heating the mill, pump, bitumen line, and filter.

The temperature and tolerance settings of the bitumen pump, as well as the start and stop time settings (hour/minute) of any heaters, are configured. Based on these settings and parameters, the heaters will automatically switch on and off. These configured values are saved to permanent memory. Heaters should not be operated when the tank is completely empty. Heaters will only be activated once there is at least 500 kg of water in the tank.

The Vimpo Bitumen Emulsion Plants is equipped with electrically controlled automatic heaters. After the bitumen pump, mill, and bitumen line heaters are activated, the water intake process begins. The required amount of water is transferred into the solution tank, and the pump is then stopped. The water is then heated to the desired temperature using the electric heaters in the tank. Once the target water temperature is reached, the preparation of the solution to be used in emulsion production begins.

The system operates automatically based on the bitumen and solution quantities specified in the selected recipe, as well as user-defined tolerance and working parameters. Once automatic production is activated, production continues until the bitumen or solution tank reaches its empty weight value.

The automated emulsion production process is sequentially carried out and monitored by the automation software. It first verifies that at least one of the emulsion discharge valves (tank or sprayer) has been selected and is open. Then, the mill is started. Approximately 10 seconds after the mill is fully running, the WAE pump is started, followed by the bitumen pump. The speeds of the bitumen and solution pumps are adjusted according to the recipe’s set and tolerance values.

The ratio between bitumen and solution is continuously maintained during production. If the amount of solution passing decreases, the bitumen amount is also decreased accordingly. Likewise, if the bitumen flow decreases, the solution flow is reduced proportionally. When the solution weight in the WAE tank reaches the empty weight value specified on the calibration page, the bitumen pump stops.

Twenty seconds after the bitumen pump stops, the WAE pump stops, and then the mill stops. Once the mill has stopped, the system exits automatic production mode.

As a second method, the Vimpo Bitumen Emulsion Plants can also be operated manually by the operator.

In manual mode, the emulsion production steps are carried out and controlled by the operator in sequence. First, it is verified that at least one of the emulsion discharge valves (tank or sprayer) is selected and open. The mill is started. Thirty seconds after the mill is fully operational, the WAE pump is started.

Sixty seconds after the WAE pump is started, the bitumen pump is started. The speeds of the bitumen and solution pumps are adjusted based on the recipe’s set and tolerance values. The ratio between bitumen and solution is continuously maintained during production. If the amount of solution passing decreases, the bitumen amount is reduced accordingly, or vice versa.

This process continues until one of the tanks reaches its empty weight value. Once one of the tanks is completely empty, the bitumen pump is stopped. Sixty seconds after the bitumen pump is stopped, the WAE pump is stopped. Thirty seconds after the WAE pump is stopped, the mill is stopped.

After emulsion production is completed, the mill should be cleaned with water.

How Does a Bitumen Emulsion Plant Work?

Bitumen emulsion plants enable highly viscous bitumen, which is typically handled at high temperatures, to be converted into a water-based emulsion. In this process, the bitumen is heated to a specific temperature, while the water phase is simultaneously prepared.

Emulsifying agents and usually acidic solutions for pH adjustment are added to the water. Both the bitumen and the water phase are directed into a high-speed mixer, typically a colloid mill. The high shear force generated in the mill disperses the bitumen into micron-sized droplets within the water.

The resulting stable emulsion can be applied at lower temperatures, which reduces energy consumption and minimizes occupational safety risks.

Key Considerations When Selecting a Bitumen Emulsion Plant

When choosing a bitumen emulsion plant, several factors must be considered, including production capacity, flexibility, and technical specifications. Compatibility with the intended emulsion type (cationic, anionic, rapid or slow breaking) is one of the most critical criteria.

The automation level of the plant—especially PLC-controlled systems—reduces operator errors and enables precise dosing. Energy systems such as thermal oil heating or electric heating can be chosen based on preference. The use of stainless steel is particularly important in acid-containing phases, as it increases corrosion resistance and extends the plant's lifespan.

Compact and portable designs are advantageous, especially for use across multiple project sites.

How to Reduce the Environmental Impact of Bitumen Emulsion Plants

To reduce the environmental impact of bitumen emulsion plants, sustainability principles should be adopted both during production and at the design stage. Using electric or energy-recovery heating systems instead of fossil fuel burners helps lower carbon emissions.

Reusing wastewater and integrating closed-loop water systems minimize water consumption and contamination. Ventilation systems equipped with filtration units can reduce VOC (volatile organic compound) emissions. Emulsion formulations should also be optimized to minimize chemical usage, thereby reducing environmentally harmful waste.

Maintenance Requirements for Trouble-Free Operation of a Bitumen Emulsion Plant

For uninterrupted production, maintenance activities should be both periodic and based on continuous monitoring. Daily inspections should check temperature readings, pressure levels, and any fluid leaks. On a weekly basis, filters should be cleaned, sensor calibrations checked, and dosing pump accuracy verified.

Monthly maintenance should include inspection of colloid mill wear, mechanical seal conditions, and heating systems. Software updates should also be performed, and automation system logs reviewed. A preventive maintenance approach should be adopted to detect and resolve potential issues before they lead to breakdowns.

What Safety Measures Should Be Taken in Operating a Bitumen Emulsion Plant?

Safe operation of the plant requires both hardware and procedural safety measures. Operators must wear appropriate personal protective equipment (PPE),especially heat-resistant clothing, gloves, and goggles. Emergency stop buttons should be easily accessible on all major equipment.

Tanks, pipes, and chemical drums within the plant should be clearly labeled, and containment trays should be used in hazardous areas. Fire suppression systems must be operational and tested regularly. Electrical systems should comply with ATEX or similar explosion-proof standards.

Common Problems Encountered in Bitumen Emulsion Plant Operation

The most common issues in bitumen emulsion plants include unstable emulsion quality, pump blockages, and temperature fluctuations. Variations in bitumen viscosity can lead to undesirable emulsion behavior. Inaccurate dosing of emulsifiers and acids may disrupt pH balance, causing the emulsion to break prematurely.

Failure to clean filters or clogged dosing lines can lead to flow issues. Additionally, sensor malfunctions or software errors in the automation system may interrupt production. These problems can be minimized through systematic maintenance and real-time data monitoring.